Substrate for liquid crystal display panel

ABSTRACT

A substrate for a liquid crystal display panel includes a first projection structure and a second projection structure and/or a depression structure, the substrate for the liquid crystal display panel includes a specific structure at a part of or near the first projection structure, the specific structure having at least one of a planar shape different from a planar shape of the second projection structure and/or the depression structure and a planar area of 2/3 times or less or 1.5 times or more than a planar area of the second projection structure and/or the depression structure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a substrate for liquid crystal displaypanel preferably used as a color filter substrate of liquid crystaldisplay device. More particularly, it relates to a substrate for liquidcrystal display panel preferably used as a color filter substrate ofliquid crystal display device in multidomain vertical alignment (MVA)mode and the like.

2. Description of the Related Art

The liquid crystal display device performs a display by controllingoptical characteristics of light from a light source using a liquidcrystal layer filled in a liquid crystal display panel, and the deviceis used in various fields because of its characteristics such as thin,light and low power consumption.

In general, a liquid crystal display panel which is a main member ofsuch a liquid crystal display device has a structure in which a liquidcrystal is sandwiched between a switching element array substrate and acolor filter (CF) substrate and a thickness (cell gap) of a liquidcrystal layer is maintained by a spacer arranged between the substrates.As the spacer, a sphere spacer formed of plastic or an inorganicmaterial and the like and a columnar spacer formed of resin material andthe like are known. It is preferable that the spacer is selectivelyarranged in a light shielding area (outside a display area) on a blackmatrix and the like so as not to lower display quality of the liquidcrystal display device. In this respect, since the sphere spacer isspread so as to be arranged on a substrate in general, a highcontrolling technique is required in order to arrange it in a desiredposition. Meanwhile, the columnar spacer can be directly formed on asubstrate by a photolithography method and the like using aphotosensitive resin and the like. Therefore, it is superior in highlyprecise arrangement. In addition, the columnar spacer formed by suchphotolithography method is called a photo spacer (PS) also.

Conventionally, after the switching element array substrate and CFsubstrate are manufactured, the liquid crystal display panel ismanufactured through a process of aligning, a process of bonding bothsubstrates, a process of filling the liquid crystal and the like. Inthis case, the liquid crystal is filled by a vacuum injecting method.According to the vacuum injecting method, after both switching elementarray substrate and CF substrate are bonded, the bonded substrate issoaked in a liquid crystal bath and the liquid crystal is filled betweenthe substrates by vacuum suction.

However, the liquid crystal display panel becomes larger recently andtherefore the filling method of the liquid crystal is changed from thevacuum injecting method to a one drop filling method (a falling-dropmethod) in order to shorten the filling time of the liquid crystal.According to the one drop filling method, after the liquid crystal isdropped on one substrate (generally, on the CF substrate), the switchingelement array substrate and the CF substrate are bonded. Therefore, theliquid crystal can be filled in several minutes even in the case of alarge-size liquid crystal display panel. Meanwhile, when the one dropfilling method is used, it is necessary to strictly control an amount ofthe liquid crystal to be dropped in order to prevent an air bubble andthe like in the liquid crystal layer. And when the liquid crystal isfilled in the liquid crystal display panel having a projection structuresuch as PS, it is necessary to precisely measure a height and the likeof the projection structure on the substrate to previously determine theamount of the liquid crystal to be dropped every cell.

As a method of measuring the height of the projection structure such asthe PS without contacting a surface measured, a measuring techniqueusing light interference (white light interference) is known, forexample. When the height of the projection structure is automaticallymeasured by the measuring technique using the while light interference,the most characteristic pattern (positioning part), distance databetween the positioning part and a reference point (base point), anddistance data between the positioning part and a top of the projectionstructure is previously set in a viewing range (measuring area) of animage recognition device. Thus, at the time of measurement, a measuringhead is moved to the measuring area to perform rough origin setting(rough alignment) and then the positioning part is searched and preciseorigin setting is performed. Then, the top (coordinate) of theprojection structure and the reference point are specified based on theabove-mentioned distance data. Finally, the vicinity of the projectionstructure is irradiated with light from a white light source in a statein which an inclination angle is kept constant to form an interferencestripe. And then height difference between the reference point and thetop of the projection structure is measured by measuring a distancebetween the interference stripes.

When the PS height is automatically measured by such a measuring device,the positioning part for the origin setting by the measuring device hasto exist on the substrate. However, when the projection structure on thesubstrate is used as the positioning part in case of the substrate forliquid crystal display panel, the positioning part could be confusedwith other patterns since many projection structures such as thecolumnar spacer and the protrusion for controlling an alignment areprovided on the substrate. In addition, it is necessary to arrange thepositioning part at a predetermined position precisely. When the PS(stacked PS) having a stacked structure is used as the positioning part,for example, the configuration of the interference stripe of the stackedPS formed by the white light interference is changed every measurementbecause of alignment shift of each layer, which causes a malfunction ofthe height measuring device. Thus, the substrate for liquid crystaldisplay panel comprising a positioning part which can be appropriatelyused in origin setting by a measuring device has been demanded when PSheight is measured.

In addition, the constitution of the columnar spacer is disclosed inmany documents, for example, a CF substrate and the like in which astacked PS is formed on a black matrix has been disclosed. However,there is no description about providing a positioning part used when theheight of the columnar spacer is measured. Refer to Japanese KokaiPublication Hei-09-120063 (Patent Document 1), Japanese KokaiPublication Hei-10-232310 (Patent Document 2), Japanese KokaiPublication Hei-11-64618 (Patent Document 3), Japanese Kokai PublicationHei-11-248921 (Patent Document 4), Japanese Kokai Publication2000-147234 (Patent Document 5), Japanese Kokai Publication No.2000-258617 (Patent Document 6), Japanese Kokai Publication No.2001-51266 (Patent Document 7), and Japanese Kokai Publication No.2002-162629 (Patent Document 8), for example.

Regarding the positioning part provided on the substrate for liquidcrystal display panel, it is disclosed that a positioning part used whenthe substrates are aligned at the time of bonding or a positioning partused in alignment of a mask at the time of forming a metal film patternin a peripheral area of the substrate is arranged. However, there isroom for improvement of a positioning part used in measuring PS heightin view of its forming method and its arrangement. Refer to JapaneseKokai Publication No. Hei-09-127546 (Patent Document 9), Japanese KokaiPublication No. Hei-09-197434 (Patent Document 10), and Japanese KokaiPublication No. Hei-10-123549 (Patent Document 11), for example.

SUMMARY OF THE INVENTION

The present invention was made in view of the above problems and it isan object of the present invention to provide a substrate for liquidcrystal display panel having a structure in which a height of aprojection structure such as a columnar spacer provided on the substratecan be automatically measured by a measuring device, a liquid crystaldisplay panel and a liquid crystal display device using it, and anexamining method of the substrate for the liquid crystal display paneland a manufacturing method of the liquid crystal display panel using it.

The inventors of the present invention have studied a method ofmeasuring a height of a projection structure such as a columnar spacerprovided on a substrate for liquid crystal display panel and focused onthe fact that a measuring technique using white light interference iseffective in automatically measuring a height of a projection structureeasily while preventing damage of a substrate. Thus, the inventors foundthat when a specific structure is provided at a part of or near a firstprojection structure to be measured as a positioning part, and thespecific structure has at least one of a planar shape different from aplanar shape of a second projection structure (an other kind projectionstructure) and/or a depression structure and a planar area of 2/3 timesor less or 1.5 times or more than a planar area of the second projectionstructure and/or the depression structure, the first projectionstructure to be measured with a measuring device could be specified andits height could be measured with high precision, even if the secondprojection structure and/or the depression structure existed on thesubstrate. Thus, the above problems were solved, leading to completionof the present invention.

That is, a substrate for liquid crystal display panel according to thepresent invention comprises a first projection structure and a secondprojection structure and/or a depression structure, the substrate forliquid crystal display panel comprising a specific structure at a partof or near the first projection structure, the specific structure havingat least one of a planar shape different from a planar shape of thesecond projection structure and/or the depression structure and a planararea of 2/3 times or less or 1.5 times or more than a planar area of thesecond projection structure and/or the depression structure. Inaddition, the projection structure is an area formed by a protrusion inthe substrate and is higher than a reference point of the height levelin the substrate. The depression structure is an area formed by a slit(groove), a hole and the like in the substrate and is lower than areference point of the height level in the substrate. The specificstructure is provided at a part of or near the first projectionstructure to be measured, and has a shape different from a part or thewhole part of the second projection structure and/or the depressionstructure, or has an area of 2/3 times or less or 1.5 times or more thanthat of the second projection structure and/or the depression structureas viewed in plane from a direction of a normal line to a substrateface. According to the present invention, the configuration in which thespecific structure has a shape different from that of a part or thewhole part of the second projection structure and/or the depressionstructure is preferable in view of effectively preventing delay of takttime (processing speed) attributed to an image processing ability.

When there are two or more kinds of the first projection structure to bemeasured on the substrate, two or more kinds of the specific structuremay be provided so as to correspond to each kind of the first projectionstructure. According to the present invention, a position of the firstprojection structure to be measured or a position of a reference pointto determine a height of reference level can be precisely specified byrecognizing the specific structure as a positioning part by a heightmeasuring device. Therefore, the height of the first projectionstructure can be automatically measured precisely.

In the case where the planar shape of the specific structure isdifferent from the second projection structure and/or the depressionstructure, it is preferable that the planar shape of the specificstructure has at least one linear part of 4 μm or more in view of aresolution limit of an image recognition device. In addition, in orderto perform precise positioning using the specific structure, it ispreferable that a viewing range (measuring area) of an image recognitiondevice and an interval between the specific structures are adjusted soas not to provide a plurality of specific structures in the viewingrange.

It is preferable that the substrate for liquid crystal display panelcomprises a columnar spacer as the first projection structure and adot-shaped protrusion for controlling an alignment as the secondprojection structure, and the specific structure is provided at a partof or near the columnar spacer. The dot-shaped protrusion forcontrolling an alignment does not easily intersect with a black matrixas the rib-shaped protrusion for controlling an alignment intersectswith a black matrix and it is difficult to use an intersecting pointwith the black matrix as the positioning part. And the dot-shapedprotrusion usually has a shape easily confused with the columnar spaceras compared with the rib-shaped protrusion for controlling an alignment.However, according to this configuration, the height of the columnarspacer can be measured because the specific structure effectivelyprevents the columnar spacer and the dot-shaped protrusion forcontrolling an alignment from being confused.

In addition, the substrate for liquid crystal display panel according tothe present invention in which the dot-shaped protrusion for controllingan alignment is provided can be applied to a multidomain verticalalignment (MVA) type liquid crystal display device.

It is preferable that the columnar spacer has a stacked structure. Inthis case, since each layer constituting the columnar spacer can besequentially formed at the step in which a colored layer is formed,manufacturing costs of a substrate for liquid crystal display panel canbe reduced. In the case of the columnar spacer having a stackedstructure, it is not preferable to use a body part of the columnarspacer formed of the stacked structure as a positioning part in generalin view of precision, since alignment of each layer could be shifted inthe step of forming the spacer. However, in this case, since thespecific structure is provided at a part of or near the columnar spacerhaving the stacked structure and used as a positioning part, highlyprecise positioning can be performed. As the specific structure, singlelayer structure is preferably used. In addition, the shape of thecolumnar spacer may be a cone or a pyramid other than a column or asquare column. Similarly, the shape of the dot-shaped protrusion forcontrolling an alignment may be a column, a square column, a cone, apyramid and the like.

Furthermore, as one preferable configuration of the columnar spacer, ablack matrix is not arranged as a base of the columnar spacer. Thisconfiguration is advantageously used when a cell thickness (thickness ofa liquid crystal layer) is thinly formed.

It is preferable that the substrate for liquid crystal display panelcomprises a specific structure formed of a black matrix near the firstprojection structure. According to this case, when the characteristicpart, which is formed by an outline of the black matrix, provided as thespecific structure, can be recognized as a positioning part, highlyprecise positioning can be performed. In addition, when the specificstructure is formed of the black matrix, the first projection structureis formed outside an area overlapping with the specific structure asviewed in plane. When the specific structure formed of the black matrixis provided not near the first projection structure but in the areaoverlapping with the first projection structure, precise positioning maybe insufficiently performed in some cases. The black matrix may beprovided nearer the liquid crystal layer (as upper layer) in relation tothe colored layer or may be provided nearer the supporting substrate (aslower layer) in relation to the colored layer. However, when the blackmatrix is provided below the colored layer, the specific structure isrecognized by a highly-sensitive image recognition device in order toprevent reduction of measurement precision due to interference betweenthe black matrix and other colored layers (red layer, for example). Inaddition, as the black matrix, instead of the resin film containing ablack pigment, a color stacked black matrix in which colored layers ofthree colors such as red, blue and green are stacked may be used.

It is preferable that the substrate for liquid crystal display panelcomprises a specific structure formed of a colored layer near the firstprojection structure. In this case, highly precise positioning can beperformed by recognizing the characteristic part, which is formed by anoutline of the colored layer, provided as the specific structure as apositioning part. In addition, when the specific structure is formed ofthe colored layer, the first projection structure is formed outside anarea overlapping with the specific structure as viewed in plane. Whenthe specific structure formed of the colored layer is provided not nearthe first projection structure but in the area overlapping with thefirst projection structure, precise positioning may insufficientlyperformed in some cases. The colored layer may be provided nearer theliquid crystal layer (as upper layer) in relation to the black matrix ormay be provided nearer the supporting substrate (as lower layer) inrelation to the black matrix. However, when the colored layer isprovided below the black matrix, the specific structure is recognized bya highly-sensitive image recognition device in order to preventreduction of measurement precision due to interference between thecolored layer and the black matrix.

The present invention also relates to a substrate for liquid crystaldisplay panel comprising a first projection structure and a secondprojection structure and/or a depression structure, the first projectionstructure having a single layer structure and a whole shape of the firstprojection structure being formed of a specific structure, and thespecific structure having at least one of a planar shape different froma planar shape of the second projection structure and/or the depressionstructure and a planar area of 2/3 times or less or 1.5 times or morethan a planar area of the second projection structure and/or thedepression structure. Thus, according to the present invention, thespecific structure may be provided as the whole shape of the firstprojection structure having the single layer structure, and theoperational advantage of the present invention can be obtained like theabove case. In this case, it is preferable that the substrate for liquidcrystal display panel comprises a columnar spacer having a single layerstructure as the first projection structure and a dot-shaped protrusionfor controlling an alignment as the second projection structure, and thewhole shape of the columnar spacer is formed of the specific structure.

According to the present invention, it is preferable that the planarshape of the dot-shaped protrusion for controlling an alignment is asubstantially circular. Thus, the alignment of the liquid crystal can beeffectively controlled, leading to improvement in display quality.

In addition, it is preferable that the specific structure is provided ona non-display area. For example, it is preferable that it is provided inan area overlapping with a black matrix formed on the substrate forliquid crystal display panel as viewed in plane or an area overlappingwith a wiring formed on a substrate facing to the substrate for liquidcrystal display panel comprising the specific structure as viewed inplane. According to those configurations, disturbance and the like inalignment of the liquid crystal caused by the specific structure has asmaller effect on display quality, since the specific structure isprovided in the non-display area (light shielding area) which is notused in display.

The present invention also relates to a substrate for liquid crystaldisplay panel comprising a projection structure(s) and a black matrix,one or more of the projection structures having a single layer structureand one or more intersecting parts of the black matrix and an outline ofthe projection structure as viewed in plane.

Thus, according to the present invention, when the intersecting part ofthe outline of the projection structure having the single layerstructure with the outline of the black matrix is recognized by a heightmeasuring device as a positioning part, the position of the projectionstructure to be measured and the position of the reference point todetermine a reference level of the height can be specified with highprecision similar to the above-mentioned configuration in which thespecific structure is provided. Therefore, the height of the projectionstructure can be precisely measured. In this case, it is preferable thatthe projection structure comprises a columnar spacer and a dot-shapedprotrusion for controlling an alignment and the dot-shaped protrusionfor controlling an alignment has a single layer structure and one ormore intersecting parts of the black matrix and an outline of thedot-shaped protrusion as viewed in plane.

The present invention also relates to a substrate for liquid crystaldisplay panel comprising a projection structure, a depression structure(s) and a black matrix, one or more of the depression structures haveone or more intersecting parts of the black matrix and an outline of thedepression structure as viewed in plane.

Thus, according to the present invention, when the intersecting point ofthe outline of the depression structure with the outline of the blackmatrix is recognized by a height measuring device as a positioning part,the position of the projection structure to be measured and the positionof the reference point to determine a reference level of the height canbe specified with high precision similar to the above-mentionedconfiguration, in which the specific structure is provided. Therefore,the height of the projection structure can be precisely measured. Inthis case, it is preferable that the projection structure comprises acolumnar spacer, the depression structure comprises a slit forcontrolling an alignment and/or a hole for controlling an alignment, andthe slit for controlling an alignment and/or the hole for controlling analignment has one or more intersecting parts of the black matrix and anoutline of the slit and/or the hole as viewed in plane.

According to the present invention, it is preferable that each cell areahas the intersecting part. In addition, each cell area means an areaused for one substrate constituting a liquid crystal display panel in amultiple substrates for liquid crystal display panels. In this case, themultiple substrates for liquid crystal display panels are divided intoplural numbers and an appropriate dropping amount of the liquid crystalcan be determined for each substrate.

In addition, according to the present invention, it is preferable thatthe specific structure or the intersecting part is substantiallyuniformly provided on the substrate surface. Thus, an optimal liquidcrystal amount dropped can be determined with higher precision. Inaddition, influence on display quality by disturbance in the alignmentof the liquid crystal caused by the specific structure can besubstantially uniform on the substrate surface.

It is preferable that the substrate for liquid crystal display panel isa color filter substrate. In a liquid crystal display panel, aprojection structure such as a columnar spacer, whose height ismeasured, is provided on the side of a color filter substrate in manycases. Therefore, it is preferable that the specific structure isprovided on the side of the color filter substrate in the presentinvention.

In addition, the present invention relates to a liquid crystal displaypanel and a liquid crystal display device comprise the above-mentionedsubstrate for liquid crystal display panel. According to the liquidcrystal display panel and the liquid crystal display device of thepresent invention, the liquid crystal display panel and the liquidcrystal display device with high display quality can be provided, sincethe height of the columnar spacer is measured using the specificstructure to optimize the liquid crystal amount dropped.

In addition, the present invention relates to a method for examining asubstrate for liquid crystal display panel comprising a columnar spacerand at least one structure for specifying a position, the methodcomprising at least: a process of specifying a position of the structurefor specifying a position; a process of determining a position of areference point and a spacer top based on predetermined distance datafrom a structure for specifying a position; and a process of measuring adifference in height between determined positions of the reference pointand the spacer top.

In this case, as the structure for specifying a position, the specificstructure or the intersecting part in the substrate for liquid crystaldisplay panel or the intersecting part of an outline of the linearlyformed protrusion for controlling an alignment and/or the slit forcontrolling an alignment with an outline of the black matrix in thepresent invention may be preferably used. As the reference point, it isnot particularly limited as long as it can be used as a reference(height is 0) when the height of the columnar spacer is measured.According to the examining method of the substrate for liquid crystaldisplay panel in the present invention, influence caused by aconstitution of the columnar spacer or a member arranged near thecolumnar space can be minimized and the height can be preciselymeasured. Also, the height can be automatically measured, when ameasuring device, in which a program to perform the above-mentionedprocesses is written, is used.

The present invention also relates to a method for manufacturing aliquid crystal display panel using the above-mentioned method forexamining the substrate for liquid crystal display panel, an amount of aliquid crystal dropped on a substrate being determined depending on adifference in height between a position of the reference point and aposition of the spacer top. According to the method for manufacturing aliquid crystal display panel, the liquid crystal display panel havinghigh display quality can be stably manufactured since the amount of theliquid crystal dropped by a one drop filling method is determined basedon the measured result of the height of the columnar spacer.

According to the substrate for liquid crystal display panel in thepresent invention, the position of the projection part to be measuredand the position of the reference point to determine the reference levelfor the height can be specified with high precision, since the specificstructure which can be recognized by a height measuring device as apositioning part is provided. Therefore, the height of the projectionstructure can be automatically measured with high precision.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 1 of the present invention, and FIG. 1 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 1 (a).

FIG. 2 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 2 of the present invention, and FIG. 2 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 2 (a).

FIG. 3 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 3 of the present invention, and FIG. 3 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 3 (a).

FIG. 4 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 4 of the present invention, and FIG. 4 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 4 (a).

FIG. 5 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 5 of the present invention, and FIG. 5 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 5 (a).

FIG. 6 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 6 of the present invention, and FIG. 6 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 6 (a).

FIG. 7 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 7 of the present invention, and FIG. 7 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 7 (a).

FIG. 8 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 8 of the present invention, and FIG. 8 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 8 (a).

FIG. 9 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 9 of the present invention, and FIG. 9 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 9 (a).

FIG. 10 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 10 of the present invention, and FIG. 10 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 10 (a).

FIG. 11 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 11 of the present invention, and FIG. 11 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 11 (a).

FIG. 12 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 12 of the present invention, and FIG. 12 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 12 (a).

FIG. 13 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 13 of the present invention, and FIG. 13 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 13 (a).

FIG. 14 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 14 of the present invention, and FIG. 14 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 14 (a).

FIG. 15 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 15 of the present invention, and FIG. 15 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 15 (a).

FIG. 16 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 16 of the present invention, and FIG. 16 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 16 (a).

FIG. 17 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 17 of the present invention, and FIG. 17 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 17 (a).

FIG. 18 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 18 of the present invention, and FIG. 18 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 18 (a).

FIG. 19 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 19 of the present invention, and FIG. 19 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 19 (a).

FIG. 20 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 20 of the present invention, and FIG. 20 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 20 (a).

FIG. 21 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 21 of the present invention, and FIG. 21 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 21 (a).

FIG. 22 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 22 of the present invention, and FIG. 22 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 22 (a).

FIG. 23 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 23 of the present invention, and FIG. 23 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 23 (a).

FIG. 24 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 24 of the present invention, and FIG. 24 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 24 (a).

FIG. 25 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 25 of the present invention, and FIG. 25 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 25 (a).

FIG. 26 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 26 of the present invention, and FIG. 26 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 26 (a).

FIG. 27 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 27 of the present invention, and FIG. 27 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 27 (a).

FIG. 28 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 28 of the present invention, and FIG. 28 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 28 (a).

FIG. 29 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 29 of the present invention, and FIG. 29 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 29 (a).

FIG. 30 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 30 of the present invention, and FIG. 30 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 30 (a).

FIG. 31 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 31 of the present invention, and FIG. 31 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 31 (a).

FIG. 32 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 32 of the present invention, and FIG. 32 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 32 (a).

FIG. 33 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 33 of the present invention, and FIG. 33 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 33 (a).

FIG. 34 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 34 of the present invention, and FIG. 34 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 34 (a).

FIG. 35 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 35 of the present invention, and FIG. 35 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 35 (a).

FIG. 36 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 36 of the present invention, and FIG. 36 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 36 (a).

FIG. 37 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 37 of the present invention, and FIG. 37 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 37 (a).

FIG. 38 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 38 of the present invention, and FIG. 38 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 38 (a).

FIG. 39 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 39 of the present invention, and FIG. 39 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 39 (a).

FIG. 40 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 40 of the present invention, and FIG. 40 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 40 (a).

FIG. 41 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 41 of the present invention, and FIG. 41 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 41 (a).

FIG. 42 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 42 of the present invention, and FIG. 42 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 42 (a).

FIG. 43 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 43 of the present invention, and FIG. 43 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 43 (a).

FIG. 44 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 44 of the present invention, and FIG. 44 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 44 (a).

FIG. 45 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 45 of the present invention, and FIG. 45 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 45 (a).

FIG. 46 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 46 of the present invention, and FIG. 46 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 46 (a).

FIG. 47 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 47 of the present invention, and FIG. 47 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 47 (a).

FIG. 48 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 48 of the present invention, and FIG. 48 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 48 (a).

FIG. 49 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 49 of the present invention, and FIG. 49 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 49 (a).

FIG. 50 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 50 of the present invention, and FIG. 50 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 50 (a).

FIG. 51 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 51 of the present invention, and FIG. 51 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 51 (a).

FIG. 52 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 52 of the present invention, and FIG. 52 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 52 (a).

FIG. 53 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 53 of the present invention, and FIG. 53 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 53 (a).

FIG. 54 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 54 of the present invention, and FIG. 54 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 54 (a).

FIG. 55 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 55 of the present invention, and FIG. 55 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 55 (a).

FIG. 56 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 56 of the present invention, and FIG. 56 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 56 (a).

FIG. 57 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 57 of the present invention, and FIG. 57 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 57 (a).

FIG. 58 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 58 of the present invention, and FIG. 58 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 58 (a).

FIG. 59 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 59 of the present invention, and FIG. 59 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 59 (a).

FIG. 60 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 60 of the present invention, and FIG. 60 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 60 (a).

FIG. 61 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 61 of the present invention, and FIG. 61 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 61 (a).

FIG. 62 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 62 of the present invention, and FIG. 62 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 62 (a).

FIG. 63 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 63 of the present invention, and FIG. 63 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 63 (a).

FIG. 64 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 64 of the present invention, and FIG. 64 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 64 (a).

FIG. 65 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 65 of the present invention, and FIG. 65 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 65 (a).

FIG. 66 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 66 of the present invention, and FIG. 66 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 66 (a).

FIG. 67 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 67 of the present invention, and FIG. 67 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 67 (a).

FIG. 68 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 68 of the present invention, and FIG. 68 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 68 (a).

FIG. 69 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 69 of the present invention, and FIG. 69 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 69 (a).

FIG. 70 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 70 of the present invention, and FIG. 70 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 70 (a).

FIG. 71 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 71 of the present invention, and FIG. 71 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 71 (a).

FIG. 72 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 72 of the present invention, and FIG. 72 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 72 (a).

FIG. 73 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 73 of the present invention, and FIG. 73 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 73 (a).

FIG. 74 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 74 of the present invention, and FIG. 74 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 74 (a).

FIG. 75 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 75 of the present invention, and FIG. 75 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 75 (a).

FIG. 76 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 76 of the present invention, and FIG. 76 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 76 (a).

FIG. 77 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 77 of the present invention, and FIG. 77 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 77 (a).

FIG. 78 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 78 of the present invention, and FIG. 78 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 78 (a).

FIG. 79 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 79 of the present invention, and FIG. 79 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 79 (a).

FIG. 80 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toExample 80 of the present invention, and FIG. 80 (b) is a schematicsection view showing the liquid crystal display panel taken along lineA-A′ in FIG. 80 (a).

FIG. 81 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toComparative Example 1, and FIG. 81 (b) is a schematic section viewshowing the liquid crystal display panel taken along line A-A′ in FIG.81 (a).

FIG. 82 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toComparative Example 2, and FIG. 82 (b) is a schematic section viewshowing the liquid crystal display panel taken along line A-A′ in FIG.82 (a).

FIG. 83 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toComparative Example 3, and FIG. 83 (b) is a schematic section viewshowing the liquid crystal display panel taken along line A-A′ in FIG.83 (a).

FIG. 84 (a) is a schematic plan view showing a constitution of a colorfilter substrate mounted on a liquid crystal display panel according toComparative Example 4, and FIG. 84 (b) is a schematic section viewshowing the liquid crystal display panel taken along line A-A′ in FIG.84 (a).

FIGS. 85-1 (a) is a schematic plan view showing a manufacturing processof a color filter (CF) substrate mounted on a liquid crystal displaydevice according to Example 1, and FIGS. 85-1 (b) is a schematic sectionview showing the CF substrate taken along line A-A′ in FIGS. 85-1 (a)(after a BM layer is formed).

FIGS. 85-2 (a) is a schematic plan view showing a manufacturing processof a color filter (CF) substrate mounted on a liquid crystal displaydevice according to Example 1, and FIGS. 85-2 (b) is a schematic sectionview showing the CF substrate taken along line A-A′ in FIGS. 85-2 (a)(after a first colored layer is formed).

FIGS. 85-3 (a) is a schematic plan view showing a manufacturing processof a color filter (CF) substrate mounted on a liquid crystal displaydevice according to Example 1, and FIGS. 85-3 (b) is a schematic sectionview showing the CF substrate taken along line A-A′ in FIGS. 85-3 (a)(after a second colored layer is formed).

FIGS. 85-4 (a) is a schematic plan view showing a manufacturing processof a color filter (CF) substrate mounted on a liquid crystal displaydevice according to Example 1, and FIGS. 85-4 (b) is a schematic sectionview showing the CF substrate taken along line A-A′ in FIGS. 85-4 (a)(after a third colored layer is formed).

FIGS. 85-5 (a) is a schematic plan view showing a manufacturing processof a color filter (CF) substrate mounted on a liquid crystal displaydevice according to Example 1, and FIGS. 85-5 (b) is a schematic sectionview showing the CF substrate taken along line A-A′ in FIGS. 85-5 (a)(after an opposed electrode is formed).

FIGS. 85-6 (a) is a schematic plan view showing a manufacturing processof a color filter (CF) substrate mounted on a liquid crystal displaydevice according to Example 1, and FIGS. 85-6 (b) is a schematic sectionview showing the CF substrate taken along line A-A′ in FIGS. 85-6 (a)(after a dot-shaped protrusion for controlling an alignment and aprotrusion material layer are formed).

FIGS. 86-1 is a schematic view showing a whole constitution (opticalsystem) of a height measuring device using white light interference.

FIGS. 86-2 is an enlarged schematic view showing a constitution of aninterferometer type objective lens (Mirau interferometer) in the heightmeasuring device shown in FIG. 86-1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will be described in more detail with reference tothe drawings hereinafter, but the present invention is not limited tothese Examples only.

Example 1

FIG. 1 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 1 of the present invention, and FIG. 1 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 1 (a).

As shown in FIG. 1 (b), the liquid crystal display panel according toExample 1 has a structure in which a liquid crystal layer 50 issandwiched between a color filter (CF) substrate 100 and a switchingelement array substrate 200.

The CF substrate 100 has a structure in which an insulating transparentsupporting substrate 10, a colored layer comprising a first coloredlayer 11 a, a second colored layer 11 b, and a third colored layer 11 cformed in a display area on the transparent supporting substrate 10, ablack matrix (BM) layer 11 d formed in a non-display area on thetransparent supporting substrate 10, an ITO transparent opposedelectrode 13 formed on the colored layer and the BM layer 11 d, aplurality of dot-shaped (rivet-shaped) protrusions for controlling analignment 14 in form of cones formed in the display are on the ITOtransparent opposed electrode 13, and a polyimide alignment layer 15formed so as to cover an entire surface of the substrate are stacked. Onthe other hand, the switching element array substrate 200 has astructure in which an array-side pattern 21 comprising a switchingelement circuit layer, an interlayer insulation film and the like, apixel electrode 23 formed in the shape of an island, and a polyimidealignment layer 25 formed so as to cover an entire surface of thesubstrate are sequentially stacked on an insulating transparentsupporting substrate 20. In addition, the polyimide alignment layers 15and 25 on the CF substrate 100 and the switching element array substrate200 respectively are formed separately after a series of substratemanufacturing processes. The switching element is not particularlylimited and it may be a thin film transistor (TFT) using amorphoussilicon, a TFT using polysilicon, a TFT using a continuous grain silicon(CGS), a thin film diode (TFD) such as MIM (Metal Insulator Metal) andthe like.

According to the liquid crystal display device in Example 1, a thickness(cell gap) of the liquid crystal layer 50 is maintained by a stacked PS(columnar spacer) 12 formed on the CF substrate 100.

According to Example 1, the stacked PS 12 has a structure in which thefirst colored layer 11 a, the second colored layer 11 b, the thirdcolored layer 11 c, and a layer (referred to also as “protrusionmaterial layer”) 14′ formed of the same material as that of thedot-shaped protrusion for controlling an alignment 14 are sequentiallystacked on the BM layer 11 d on the side of the transparent supportingsubstrate 10. According to the first colored layer 11 a, a partconstituting the stacked PS 12 and a part constituting the display areaare integrated and the part constituting the stacked PS 12 is locatedabove the BM layer 11 d. According to the second colored layer 11 b, apart constituting the stacked PS 12 and a part constituting the displayarea are separated and the part constituting the stacked PS 12 has acircular planar shape and formed on a part of the first colored layer 11a. According to the third colored layer 11 c, a part constituting thestacked PS 12 and a part constituting the display area are separated andthe part constituting the stacked PS 12 is formed in the center of thesecond colored layer 11 b concentrically with the second colored layer11 b. The protrusion material layer 14′, which is the uppermost layer,has a lower end positioned on the first colored layer 11 a, and entirelycovers the second colored layer 11 b and the third colored layer 11 c.And the layer 14′ has a flat top and a main part (a stacked part whichserves as a spacer except for a specific structure 8) having a planarshape of circle. In addition, the rectangular specific structure 8 isprovided on the protrusion material layer 14′ as shown by dotted line inthe drawing, and a part of the structure 8 sticks out from the BM layer11 d.

Thus, the stacked PS 12 according to this Example has a substantiallycone shape in which the top is a flat face and has the rectangularspecific structure 8 at the bottom.

One example of a method for manufacturing a liquid crystal displaydevice according to Example 1 will be described hereinafter, but thepresent invention is not limited to this example.

FIGS. 85-1 (a), 85-2 (a), 85-3 (a), 85-4 (a), 85-5 (a), and 85-6 (a) areschematic plan views showing manufacturing steps of a color filter (CF)substrate mounted on a liquid crystal display device according toExample 1, and FIGS. 85-1 (b), 85-2 (b), 85-3 (b), 85-4 (b), 85-5 (b),and 85-6 (b) are schematic section views respectively showing the CFsubstrate taken along lines A-A′ in FIGS. 85-1 to 85-6 (a)s.

First, the insulating transparent supporting substrate 10 is prepared.The insulating transparent supporting substrate 10 is not particularlylimited, but a glass substrate is preferable. Then, as shown in FIGS.85-1, the black matrix (BM) layer 11 d is patterned on the transparentsupporting substrate 10. Then, as shown in FIGS. 85-2 to 85-4, thecolored layers such as the first colored layer 11 a, the second coloredlayer 11 b and the third colored layer 11 c are sequentially patterned.At this time, a part of the patterns of the colored layers issequentially stacked at a place in which the stacked PS 12 is arranged.Then, the opposed electrode 13 is formed as shown in FIGS. 85-5. Theopposed electrode 13 is generally formed of a transparent conductivematerial, and especially indium tin oxide (ITO), indium zinc oxide (IZO)and the like are preferably used. A method of forming the opposedelectrode 13 is not particularly limited and a sputtering may bementioned, for example. Then, as shown in FIGS. 85-6, the dot-shapedprotrusion for controlling an alignment 14 and the protrusion materiallayer 14′, which is the uppermost layer of the stacked PS, are formed atthe same time. As a material of the dot-shaped protrusion forcontrolling an alignment 14 and the protrusion material layer 14′, aphotosensitive resin is preferable and especially, a positive typephotosensitive resin such as an acrylic resin, a polyimide resin, anovolac resin is preferable. In addition, methods of forming the BMlayer 11 d, the colored layers, the alignment controlling protrusion 14and the protrusion material layer 14′ are not particularly limited. Forexample, a photolithography method, in which a liquid material isapplied by slit and spin coating or slot coating and then exposure,development and baking are performed, a dry film laminating (transfer)method, an ink jet method and the like may be used. Thus, the colorfilter (CF) substrate 100 is completed. Then, as shown in FIG. 1, beforethe substrate 100 is bonded to the switching element array substrate200, the alignment layer 15 is formed on the whole surface of thesubstrate. The alignment layer 15 is preferably a vertical alignmentlayer and as a material of the vertical alignment layer, a polyimideresin is preferably used, for example. In general, the alignment layer15 is subjected to a rubbing process after formation of the alignmentlayer 15. However, the rubbing process may not be performed when thevertical alignment layer is formed. In some cases, the alignment layer15 itself may not be formed.

Then, a height of the stacked PS 12 formed on the CF substrate 100 ismeasured with a height measuring device which uses white lightinterference as shown in FIGS. 86-1 and 86-2. More specifically, thespecific structure is searched and automatically positioned with highprecision in a viewing range of an image recognition device. The imagerecognition device may be integrated with a height measuring device ormay be separated type which can be connected to the height measuringdevice. Then, the reference point and the top of the columnar spacer canbe automatically specified based on predetermined distance data from thespecified structure to a reference point and to a spacer top. Adifference in height between the reference point and the columnar spacertop, that is, the height of the columnar spacer is automaticallymeasured with a height measuring device using the white lightinterference.

Based on thus-obtained measurement results, an amount of the liquidcrystal dropped is determined and an appropriate amount of the liquidcrystal is applied onto the CF substrate 100 with a dispenser fordropping liquid crystal and the like. The liquid crystal materialdropped and filled is not particularly limited, but it preferably has anegative dielectric anisotropy (Δε<0).

Finally, the CF substrate 100 is bonded to the switching element arraysubstrate 200 manufactured separately by a conventional well-knownmethod on which the alignment layer 25 is formed, with a sealingmaterial (not shown) therebetween, whereby the liquid crystal displaydevice is completed.

According to the CF substrate 100 in the above-described Example 1, theheight of the stacked PS 12 can be automatically measured with a heightmeasuring device, since the image recognition device can recognize theentire specific structure 8, a linear part and an angular part of thespecific structure 8, an intersecting part of an outline of the specificstructure 8 and an outline of the BM layer 11 d and the like as apositioning pattern, As a result, the liquid crystal amount dropped onthe CF substrate 100 can be calculated with high precision in theprocess of bonding the CF substrate 100 to the switching element arraysubstrate 200. Therefore, a highly reliable liquid crystal displaypanel, in which the liquid crystal is filled by a one drop fillingmethod and appropriate amount of the liquid crystal is filled. Inaddition, the alignment between the CF substrate 100 and the switchingelement array substrate 200 at the bonding process can be performedusing the specific structure 8.

The specific structure 8 is provided so as to stick out from the BMlayer 11 d on the CF substrate 100 according to Example 1, butdisturbance in the alignment of the liquid crystal due to the specificstructure 8 hardly affects display quality since the structure 8 isprovided in an area overlapping with a light-shielding area of thearray-side pattern 21 of the switching element array substrate 200 asviewed in plane. In addition, an extended part from the protrusionmaterial layer 14′ having the specific structure 8 may be formed so asto be connected to the dot-shaped protrusion for controlling analignment 14.

An angular part of 90° is formed also in the BM layer 11 d on the CFsubstrate 100 in Example 1. However, an outlined part (projection part)of the BM 11 d, in which the angular part of 90° is formed, overlapswith the stacked PS 12 as viewed in plane, and therefore it is difficultto recognize the outlined part as a pattern by an image recognitiondevice. In addition, an angular part of 135° is also formed in the BMlayer 11 d, but it is regarded as a substantially circle shape becauseof its large angle, and it is confused with the dot-shaped protrusionfor controlling an alignment 14 having a planar shape of substantiallycircle. Therefore, the angular part of the 135° is not recognized as thespecific pattern by an image recognition device. Similarly, when thedot-shaped protrusion for controlling an alignment 14 has a planar shapeof substantially circle, it is highly likely that not only the circlebut also an ellipse or a polygon such as a regular octagon, a regulardodecagon or the like is confused.

In addition, a combination of the colored layers (the first coloredlayer 11 a, the second colored layer 11 b and the third colored layer 11c) is not particularly limited, and a combination of a red layer (R), agreen layer (G), and a blue layer (B), or a combination of a cyan layer(C), a yellow layer (Y), a magenta layer (M) may be used, or acombination of three colors other than the above combinations may beused. Furthermore, according to the present invention, the combinationof colored layers may comprise four colors or more, and a white layer(W) may be added, for example.

In the CF substrate 100 of Example 1, the stacked PS 12 has a structurein which the first colored layer 11 a, the second colored layer 11 b,the third colored layer 11 c and the protrusion material layer 14′formed of the same material as that of the colored layer in pixel areaare sequentially stacked on the side of the transparent supportingsubstrate 10. However, the kind of the colored layer and the order ofstacked layers, the number of the stacked layers and the like are notparticularly limited in the present invention. That is, the stacked PS12 may comprise, instead of the first colored layer, a fourth coloredlayer which is not formed in the pixel area, or may have the secondcolored layer 11 b as the lowermost layer, or may comprise four or morestacked layers. Similarly, in the CF substrate 100 according to Example1, the second colored layer 11 b and the third colored layer 11 c in thepart constituting the stacked PS 12 are separated from those in the partconstituting the display area. However, the structure of the coloredlayers constituting the stacked PS 12 is not particularly limited in thepresent invention, and the part constituting the stacked PS 12 and thepart constituting the display area may be integrally provided.

In addition, in the substrate 100 according to Example 1, the stacked PS12 is stacked on the BM layer 11 d, but the stacked PS may not have theBM layer as a base. That is, when the BM layer is not arranged, thefirst colored layer is provided as a base and the second and thirdcolored layers may be provided thereon in the shape of dots.

Example 2

FIG. 2 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 2 of the present invention, and FIG. 2 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 2( a).

The liquid crystal display panel according to Example 2 has the sameconstitution as that of the liquid crystal display panel according toExample 1 except that the third colored layer 11 c in the stacked PS 12is provided so as to cover the second colored layer 11 b. The sameoperation effect as that in Example 1 can be provided also in the liquidcrystal display panel of Example 2.

Example 3

FIG. 3 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 3 of the present invention, and FIG. 3 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 3 (a).

The liquid crystal display panel according to Example 3 is the same asthat of the liquid crystal display panel according to Example 1 exceptthat the stacked PS 12 does not comprise the second colored layer 11 b.That is, according to Example 3, the stacked PS 12 has a structure inwhich the first colored layer 11 a, the third colored layer 11 c and theprotrusion material layer 14′ are sequentially stacked on the BM layer11 d from the side of the transparent supporting substrate 10. The sameoperation effect as that in Example 1 can be provided also in the liquidcrystal display panel of Example 3.

In addition, even when the stacked PS 12 has a structure in which thefirst colored layer 11 a, the second colored layer 11 b and theprotrusion material layer 14′ are sequentially stacked on the BM layer11 d from the side of the transparent supporting substrate 10, the sameoperation effect as that of Example 1 can be also provided.

Example 4

FIG. 4 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 4 of the present invention, and FIG. 4 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 4 (a).

According to Example 4, the stacked PS 12 has a constitution in whichthe first colored layer 11 a and the protrusion material layer 14″ aresequentially stacked from the side of the transparent supportingsubstrate 10. According to the first colored layer 11 a, a partconstituting the stacked PS 12 and a part constituting a display areaare integrally formed and the part constituting the stacked PS 12 islocated above the BM layer 11 d. The protrusion material layer 14″ isformed in the shape of a column on a part of the first colored layer 11a. Also, as shown by a dotted line in the drawing, the rectangularspecific structure 8 formed of the same material as that of theprotrusion material layer 14″ is provided near the stacked PS 12 so asto stick out from the BM layer 11 d.

As for the other constitutions, the liquid crystal display panelaccording to Example 4 is the same as that of the liquid crystal displaypanel according to Example 1.

The same operation effect as that in Example 1 can be provided also inthe liquid crystal display of Example 4.

Examples 5 to 8

FIGS. 5 (a), 6 (a), 7 (a), and 8 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 5 to 8 of the present invention,and FIGS. 5 (b), 6 (b), 7 (b), 8 (b) are schematic section viewsrespectively showing the liquid crystal display panels taken along linesA-A′ in FIGS. 5 to 8( a)s.

The liquid crystal display panels according to Examples 5 to 8respectively have the same constitutions as those according to Examples1 to 4, except that the specific structure 8 (surrounded by a circle inthe drawings) is formed so as not to stick out from the BM layer 11 d.

According to the liquid crystal display panels according to Examples 5to 8, the same operation effect as those in Examples 1 to 4 can beprovided, since the entire specific structure 8, a linear part and anangular part of the specific structure 8 and the like can be recognizedby an image recognition device as a positioning pattern, In addition,according to the liquid crystal display panels in Examples 5 to 8, thespecific structure 8 does not necessarily overlap with a light shieldingarea on the switching element array substrate 200 since the specificstructure 8 (surrounded by a dotted line) does not stick out from the BMlayer 11 d, and therefore, a degree of freedom in design can beimproved.

Examples 9 to 12

FIGS. 9 (a), 10 (a), 11 (a), and 12 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 9 to 12 of the present invention,and FIGS. 9 (b), 10 (b), 11 (b), and 12 (b) are schematic section viewsshowing the liquid crystal display panels taken along lines A-A′ inFIGS. 9 to 12 (a)s.

The liquid crystal display panels according to Examples 9 to 12respectively have the same constitutions as those according to Examples1 to 4, except that the specific structure 8 (surrounded by a dottedline in the drawings) is not formed in alight shielding area but it isformed at a dot-shaped protrusion for controlling an alignment near thestacked PS 12.

According to the liquid crystal display panels in Examples 9 to 12, thesame operation effects as those in Examples 1 to 4 can be provided,since the entire specific structure 8, and a linear part and an angularpart of the specific structure 8 can be recognized by an imagerecognition device as a positioning pattern.

Examples 13 to 17

FIGS. 13 (a), 14 (a), 15 (a), 16 (a), and 17 (a) are schematic planviews showing constitutions of color filter (CF) substrates mounted onliquid crystal display panels according to Examples 13 to 17 of thepresent invention, and FIGS. 13 (b), 14 (b), 15 (b), 16 (b), 17 (b) areschematic section views showing the liquid crystal display panels takenalong lines A-A′ in FIGS. 13 to 17 (a)s.

According to the liquid crystal display panels in Examples 13 to 17, apair of triangular or quadrangular specific structures 8 formed of thesame material as that of the protrusion material layer 14′ is formed ona BM layer 11 d near the stacked PS 12 as shown by dotted lines in thedrawings.

As for the other constitutions, the liquid crystal display panels inExamples 13 to 17 respectively have the same configurations as those ofthe liquid crystal display panels in Examples 5 to 8.

The same operation effects as those in Examples 5 to 8 can be providedalso in the liquid crystal display panels of Examples 13 to 17.

In addition, the planar shape of the specific structure 8 in thisExample is not particularly limited to the triangle or the quadrangleand it may be any shape.

Examples 18 to 20

FIGS. 18 (a), 19 (a), and 20 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 18 to 20 of the present invention,and FIGS. 18 (b), 19 (b), and 20 (b) are schematic section views showingthe liquid crystal display panels taken along lines A-A′ in FIGS. 18 to20 (a)s.

The liquid crystal display panels according to Examples 18 to 29respectively have the same configurations as those according to Examples5 to 7, except that the planar specific structure 8 comprising a linearpart or an angular part at a part of the protrusion material layers 14′and 14″ in the stacked PS 12 is formed.

The same operation effects as those in Examples 5 to 8 can be providedalso in the liquid crystal display panels of Examples 18 to 20.

Examples 21 to 35

FIGS. 21 to 35 (a)s are schematic plan views showing constitutions ofcolor filter (CF) substrates mounted on liquid crystal display panelsaccording to Examples 21 to 35 of the present invention, and FIGS. 21 to35 (b)s are schematic section views respectively showing the liquidcrystal display panels taken along lines A-A′ in FIGS. 21 to 35 (a)s.

The liquid crystal display panels according to Examples 21 to 35respectively have the same configurations as those of the liquid crystaldisplay panels according to Examples 1 to 3, 5 to 7, 9 to 11, 13 to 15,and 18 to 20, except that a main part (a stacked part which serves as aspacer except for the specific structure 8) of the protrusion materiallayer 14′ in a stacked PS 12 has a planar shape of octagon. In addition,the octagon is not preferable as the specific structure, since it isrecognized as a substantially circular shape by an image recognitiondevice.

The same operation effects as those in Examples 1 to 3, 5 to 7, 9 to 11,13 to 15, and 18 to 20, respectively can be provided also in the liquidcrystal display panels of Examples 21 to 35.

Examples 36 to 38

FIGS. 36 (a), 37 (a), and 38 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 36 to 38 of the present invention,and FIGS. 46 (b), 47 (b), and 48 (b) are schematic section viewsrespectively showing the liquid crystal display panels taken along linesA-A′ in FIGS. 36 to 38 (a)s.

The liquid crystal display panels according to Examples 36 to 38respectively have the same configuration as those according to Examples1 to 3, except that the BM layer 11 d is not provided.

The same operation effects as those in Examples 1 to 3 can be providedalso in the liquid crystal display panels of Examples 36 to 38.

Example 39

FIG. 39 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 39 of the present invention, and FIG. 39 (b) is aschematic section view showing the liquid crystal display panel takenalong a line A-A′ in FIG. 39( a).

According to the liquid crystal display panel of Example 39, the singlelayer photo spacer 2 itself has a specific structure 8, since the singlelayer photo spacer 2 formed on the BM layer 11 d has a planar shape ofquadrangle.

The same operation effect as that in Example 1 can be provided also inthe liquid crystal display panel of Example 39.

In addition, the single layer photo spacer 2 may have a configuration inwhich the BM layer 11 d serving as a base layer and an outline of thesingle layer photo spacer 2 overlap with each other as viewed in plane.Furthermore, the planar shape of the single layer photo spacer 2 is notlimited to the quadrangle and it may be any shape.

Example 40

FIG. 40 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 40 of the present invention, and FIG. 40 (b) is aschematic section view showing the liquid crystal display panel takenalong a line A-A′ in FIG. 40 (a).

The liquid crystal display panel according to Example 40 has the sameconstitution as that of the liquid crystal display panel according toExample 39 except that the single layer photo spacer 2 having thespecific structure 8 is not formed on the BM layer 11 d.

The same operation effect as that in Example 1 can be provided also inthe liquid crystal display panel of Example 40.

Examples 41 and 42

FIGS. 41 (a) and 42 (a) are schematic plan views respectively showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 41 and 42 of the present invention,and FIGS. 41 (b) and 42 (b) are schematic section views respectivelyshowing the liquid crystal display panels taken along lines A-A′ inFIGS. 41 (a) and 42 (a).

The liquid crystal display panel according to Examples 41 and 42respectively have the same constitution as those of the liquid crystaldisplay panels according to Examples 39 and 40, except that a planararea of the single layer photo spacer 2 is 1.5 times or more than thatof the protrusion for controlling an alignment 14.

The same operation effect as that in Example 1 can be provided also inthe liquid crystal display panels of Examples 41 and 42.

Examples 43 to 45

FIGS. 43 (a), 44 (a), and 45 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 43 to 45 of the present invention,and FIGS. 43 (b), 44 (b), and 45 (b) are schematic section viewsrespectively showing the liquid crystal display panels taken along linesA-A′ in FIGS. 43 to 45 (a)s.

The liquid crystal display panels according to Examples 43 to 45respectively have the same constitutions as those of the liquid crystaldisplay panels according to Examples 1 to 3, except that a protrusionfor controlling an alignment 64 has a rib (linear) shape, and thecircular protrusion material layer 14′, which is the uppermost layer ofthe stacked PS 12, and the protrusion for controlling an alignment 64are integrally formed.

According to the liquid crystal display panels in Examples 43 to 45, aheight of the stacked PS 12 can be automatically measured with a heightmeasuring device, since an intersecting part of an outline of theprotrusion for controlling an alignment 64 and an outline of the BMlayer 11 d can be recognized by an image recognition device as apositioning pattern.

Examples 46 to 48

FIGS. 46 (a), 47 (a), and 48 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 46 to 48 of the present invention,and FIGS. 46 (b), 47 (b), and 48 (b) are schematic section viewsrespectively showing the liquid crystal display panels taken along linesA-A′ in FIGS. 46 to 48 (a)s.

The liquid crystal display panels according to Examples 46 to 48respectively have the same constitutions as those of the liquid crystaldisplay panels according to Examples 43 to 45, except that the circularprotrusion material layer 14′, which is the uppermost layer of thestacked PS 12, is not connected to the rib-shaped protrusion forcontrolling an alignment 64.

Thus, according to the liquid crystal display panels in Examples 46 to48, a height of the stacked PS 12 can be automatically measured with aheight measuring device, since an intersecting part of an outline of theprotrusion for controlling an alignment 64 and an outline of the BMlayer 11 d, which is recognized as a specific pattern by an imagerecognition device, exists.

Examples 49 to 54

FIGS. 49 to 54 (a)s are schematic plan views showing constitutions ofcolor filter (CF) substrates mounted on liquid crystal display panelsaccording to Examples 49 to 54 of the present invention, and FIGS. 49 to54 (b)s are schematic section views respectively showing the liquidcrystal display panels taken along lines A-A′ in FIGS. 49 to 54 (a)s.

The liquid crystal display panels according to Examples 49 to 54respectively have the same constitutions as those of the liquid crystaldisplay panels according to Examples 43 to 48, except that theprotrusion material layer 14′, which is the uppermost layer of thestacked PS 12, has a planar shape of octagon.

Thus, according to the liquid crystal display panels in Examples 49 to54, a height of the stacked PS 12 can be automatically measured with aheight measuring device since an intersecting part of an outline of theprotrusion for controlling an alignment 64 and an outline of the BMlayer 11 d, which is recognized as a specific pattern by an imagerecognition device, exists. In addition, the planar shape (octagon) ofthe protrusion material layer 14′ is not preferable as a specificpattern since it is recognized as a substantially circular shape by animage recognition device.

Examples 55 to 57

FIGS. 55 (a), 56 (a), and 57 (a) are schematic plan views showingconstitutions of color filter (CF) substrates mounted on liquid crystaldisplay panels according to Examples 55 to 57 of the present invention,and FIGS. 55 (b) to 57 (b) are schematic section views respectivelyshowing the liquid crystal display panels taken along lines A-A′ inFIGS. 55 to 57 (a)s.

The liquid crystal display panels according to Examples 55 to 57respectively have the same constitutions as those of the liquid crystaldisplay panels according to Examples 52 to 54, except that a rectangularprotrusion is provided on the BM layer 11 d as the specific structure 8.

According to the liquid crystal display panels in Examples 55 to 57, aheight of the stacked PS 12 can be automatically measured with a heightmeasuring device since the specific structure 8 provided on the BM layer11 d can be recognized by an image recognition device as a positioningpatter. In addition, an intersecting part of an outline of therib-shaped protrusion for controlling an alignment 64 and an outline ofthe BM layer 11 d can be by an image recognition device as a positioningpattern.

Example 58

FIG. 58 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 58 of the present invention, and FIG. 58 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 58( a).

The liquid crystal display panel according to Example 58 has the sameconstitution as that of the liquid crystal display panels according toExamples 55 to 57 except that the stacked PS 12 has the sameconfiguration as that of Example 4.

The same operation effect as that in Example 55 can be provided also inthe liquid crystal panel of Example 58.

As shown in Examples 55 to 58, when the specific structure 8 is providedon the BM layer 11 d, the structure of the stacked PS 12 is notparticularly limited. Also, the planer shape of the stacked PS 12 is notlimited to the octagon shown in Examples 55 to 58 and it may be acircle, an ellipse, a quadrangle and the like.

Examples 59 to 66

Examples 59 to 66 show various shapes of the specific structure 8 formedusing a BM layer 11 d.

FIGS. 59 to 66 (a)s are schematic plan views showing constitutions ofcolor filter (CF) substrates mounted on liquid crystal display panelsaccording to Examples 59 to 66 of the present invention, and FIGS. 59(b) to 66(b) are schematic section views respectively showing the liquidcrystal display panels taken along lines A-A′ in FIGS. 59 to 66 (a)s.

The liquid crystal display panel according to Example 59 has the sameconstitution as that of the liquid crystal display panel according toExample 55 except that the specific structure 8 is a trapezoidalprotrusion provided on the BM layer 11 d. The liquid crystal displaypanels according to Examples 60 and 61 have the same constitution asthat of the liquid crystal display panel according to Example 55 exceptthat the specific structure 8 is a triangular or a rectangular cut partprovided on the BM layer 11 d. The liquid crystal display panelaccording to Example 62 has the same constitution as that of the liquidcrystal display panel according to Example 55 except that the specificstructure 8 is provided on the side of the stacked PS 12. The liquidcrystal display panel according to Example 63 has the same constitutionas that of the liquid crystal display panel according to Example 55except that the BM layer lid is provided on colored layers 11 a to 11 c(nearer a liquid crystal layer 50). In addition, the liquid crystaldisplay panels according to Examples 64 to 66 have the same constitutionas that of the liquid crystal display panel according to Example 55except that the specific structure 8 is an island part of a rectangle,an octagon or a pentagon having a cut part, provided in the coloredlayer 11 a, the protrusion for controlling an alignment 14 iscone-shaped dot (rivet), and the stacked PS 12 has a planar shape ofcircle. The same effects as that of Example 55 can be provided also inthe liquid crystal display panels of Examples 59 to 66.

Examples 67 to 78

Examples 67 to 78 show various shapes of the specific structure 8 formedusing colored layers 11 a, 11 b and 11 c.

FIGS. 67 to 78 (a)s are schematic plan views showing constitutions ofcolor filter (CF) substrates mounted on liquid crystal display panelsaccording to Examples 67 to 78 of the present invention, and FIGS. 67 to78 (b)s are schematic section views respectively showing the liquidcrystal display panels taken along lines A-A′ in FIGS. 67 to 78 (a)s.

The liquid crystal display panels according to Examples 67 to 78 havethe same constitutions as those of the liquid crystal display panelsaccording to Examples 55 to 66 except that the specific structure 8 isprovided using the colored layers 11 a, 11 b and 11 c instead of usingthe BM layer 11 d. Thus, according to the present invention, thespecific structure 8 having the same constitution may be formed usingthe colored layers 11 a, 11 b and 11 c instead of using the BM layer 11d. The specific structure 8 is formed using the colored layer 11 c inFIGS. 67 to 73 (Examples 67 to 73) and FIGS. 75 to 78 (Examples 75 to78), but the specific structure 8 is formed using the colored layer 11 ain FIG. 74 (Example 74), since it is provided on the side of the stackedPS 12, According to the liquid crystal display panels according toExamples 67 to 78, a height of the stacked PS 12 can be automaticallymeasured with a height measuring device, since the specific structure 8formed using the colored layers 11 a, 11 b and 11 c can be recognized byan image recognition device as a positioning pattern. In addition, anintersecting part of an outline of the rib-shaped protrusion forcontrolling an alignment 64 and an outline of the BM layer 11 d can bealso recognized by an image recognition device as a positioning pattern.

Example 79

Example 79 shows a configuration in which a BM layer is not arranged asa base of the stacked PS and a rectangular specific structure is formedusing the BM layer.

FIG. 79 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 79 of the present invention, and FIG. 79 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 79 (a).

As shown in FIG. 79 (b), the liquid crystal display panel according toExample 79 has a structure in which a liquid crystal layer 50 issandwiched between the color filter (CF) substrate 100 and the switchingelement array substrate 200.

The CF substrate 100 has a structure in which the insulating transparentsupporting substrate 10, the colored layers comprising the first coloredlayer 11 a, the second colored layer 11 b, and the third colored layer11 c formed in a display area on the transparent supporting substrate10, the black matrix (BM) layer 11 d formed in a non-display area on thetransparent supporting substrate 10, the ITO transparent opposedelectrode 13 formed on the colored layers and the BM layer 11 d, aplurality of dot-shaped (rivet-shaped) protrusions for controlling analignment 14 in form of cones formed in the display area on the ITOtransparent opposed electrode 13, and the polyimide alignment layer 15formed so as to cover an entire substrate surface are stacked. On theother hand, the switching element array substrate 200 has a structure inwhich the array-side pattern 21 comprising a switching element circuitlayer, an interlayer insulation film and the like, the pixel electrode23 formed in shape of an island, and the polyimide alignment layer 25are sequentially stacked on the insulating transparent supportingsubstrate 20. In addition, the polyimide alignment layers 15 and 25 onthe CF substrate 100 and the switching element array substrate 200respectively are formed separately after a series of substratemanufacturing processes. The switching element is not particularlylimited and it may be a thin film transistor (TFT) using amorphoussilicon, a TFT using polysilicon, a TFT using a continuous grain silicon(CGS), a thin film diode (TFD) such as MIM (Metal Insulator Metal) andthe like.

According to the liquid crystal display device in Example 79, athickness (cell gap) of the liquid crystal layer 50 is maintained by thestacked PS (columnar spacer) 12 formed on the CF substrate 100.According to Example 79, the stacked PS 12 has a structure in which thefirst colored layer 11 a, the second colored layer 11 b, the thirdcolored layer 11 c and the protrusion material layer 14′ formed of thesame material as that of the dot-shaped protrusion for controlling analignment 14 are sequentially stacked from the side of the transparentsupporting substrate 10. According to the first colored layer 11 a, apart constituting the stacked PS 12 and a part constituting the displayarea are integrated. According to the second colored layer 11 b, a partconstituting the stacked PS 12 and a part constituting the display areaare separated and the part constituting the stacked PS 12 has a circularplanar shape and formed on a part of the first colored layer 11 a.According to the third colored layer 11 c, a part constituting thestacked PS 12 and a part constituting the display area are separated andthe part constituting the stacked PS 12 is formed in the center of thesecond colored layer 11 b centrically with the second colored layer 11b. According to the protrusion material layer 14′, which is theuppermost layer, has a lower end positioned on the first colored layer11 a, and entirely covers the second colored layer 11 b and the thirdcolored layer 11 c. And the layer 14′ has a top of a flat cone shape(its tip end is cut) and having a planar shape of circle. In addition,the rectangular specific structure 8 is provided on the black matrix(BM) layer lid on the side opposite to the stacked PS 12 as shown bydotted line in the drawing.

According to the CF substrate 100 in the above-described Example 79, aheight of the stacked PS 12 can be automatically measured with a heightmeasuring device, since an image recognition device can recognize theentire specific structure 8, a linear part and an angular part of thespecific structure 8, an intersecting part of an outline of the specificstructure 8 and an outline of the BM layer 11 d and the like as apositioning pattern.

In addition, according to the CF substrate 100 in Example 79,disturbance in an alignment of the liquid crystal due to the specificstructure 8 hardly affects display quality, since the specific structure8 is provided in an area overlapping with a light shielding area of thearray-side pattern 21 of the switching element array substrate 200 asviewed in plane, and an aperture ratio is not lowered due to thespecific structure 8.

In addition, the CF substrate 100 according to Example 79 hascharacteristics such that (1) it is advantageous in that a cellthickness (thickness of the liquid crystal layer 50) makes thin becausethe BM layer 11 d is not arranged as a base of the stacked PS (columnarspacer), and (2) its structure is more simplified because the specificstructure 8 is formed on the side opposite to the stacked PS (columnarspacer) 12 using the BM layer 11 d and therefore the specific structure8 is within a viewing range (measurement area) of the image recognitiondevice, as compared with the case where the specific structure 8 isformed using the colored layers 11 a, 11 b and 11 c.

In addition, according to Example 79, a combination of the coloredlayers (the first colored layer 11 a, the second colored layer 11 b andthe third colored layer 11 c) is not particularly limited, and acombination of a red layer (R), a green layer (G), and a blue layer (B),or a combination of a cyan layer (C), a yellow layer (Y), a magentalayer (M) may be used, or a combination of three colors other than theabove-mentioned colors may be used. Furthermore, according to thepresent invention, the colored layers may comprise four colors or more,and a white layer (W) may be added, for example.

In the CF substrate 100 of Example 79, the stacked PS 12 has a structurein which the first colored layer 11 a, the second colored layer 11 b andthe third colored layer 11 c formed of the same material as that of thecolored layer in a pixel area, and the protrusion material layer 14′ aresequentially stacked from the side of the transparent supportingsubstrate 10. However, the kind of the colored layer and the order ofstacked layers, the number of the stacked layers and the like are notparticularly limited in the present invention. That is, the stacked PS12 may comprise, instead of the first colored layer, a fourth coloredlayer which is not formed in the pixel area, or may have the secondcolored layer 11 b as the lowermost layer, or may comprise four or morestacked layers.

Similarly, in the CF substrate 100 according to Example 79, the secondcolored layer 11 b and the third colored layer 11 c in the partconstituting the stacked PS 12 are separated from those in the partconstituting the display area. However, the structure of the coloredlayers constituting the stacked PS 12 is not particularly limited in thepresent invention, and the part constituting the stacked PS 12 and thepart constituting the display area may be integrally provided.

In addition, in the CF substrate 100 according to Example 79, thestacked structure of the colored layers in the stacked PS 12 may bechanged, and it may be changed to the stacked PS 12 having the structureshown in FIGS. 2 to 4.

Furthermore, in the CF substrate 100 according to Example 79, the shapeof the specific structure 8 may be changed as long as it can berecognized by an image recognition device as a positioning pattern, andit may be changed to the trapezoidal specific structure 8 provided onthe BM layer 11 d shown in FIG. 59.

Furthermore, the constitution of the CF substrate 100 according toExample 79 may be changed to a constitution in which the BM layer 11 dis provided on the colored layers 11 a to 11 c (on the side of theliquid crystal layer 50).

Example 80

FIG. 80 (a) is a schematic plan view showing a constitution of a colorfilter (CF) substrate mounted on a liquid crystal display panelaccording to Example 80 of the present invention, and FIG. 80 (b) is aschematic section view showing the liquid crystal display panel takenalong line A-A′ in FIG. 80( a).

The liquid crystal display panel according to Example 80 has the sameconstitution as that of the liquid crystal display panel according toExample 79 except that the protrusion for controlling an alignment 64 isin rib (linear) shape and the circular protrusion material layer 14′,which is the uppermost layer of the stacked PS 12, and the protrusionfor controlling an alignment 64 are integrally formed.

Also in the CF substrate 100 in this Example 80, a height of the stackedPS 12 can be automatically measured with a height measuring device,since the whole of the specific structure 8 and a linear part and anangular part of the specific structure 8 provided on the BM layer 11 dcan be recognized by an image recognition device as a positioningpattern.

In addition, the present invention is not limited to the constitution inwhich the protrusion material layer 14′, which is the uppermost layer ofthe stacked PS 12, and the protrusion for controlling an alignment 64are integrally formed, the circular protrusion material layer 14′ whichis the uppermost layer of the stacked PS 12 and the rib-shapedprotrusion for controlling an alignment 64 may not be connected.

Comparative Examples 1 to 4

FIGS. 81 (a), 82 (a), 83 (a), and 84 (a) are schematic plan viewsshowing constitutions of color filter (CF) substrates mounted on liquidcrystal display panels according to Comparative Examples 1 to 4, andFIGS. 81 (b), 82 (b), 83 (b), and 84 (b) are schematic section viewsrespectively showing the liquid crystal display panels taken along linesA-A′ in FIGS. 81 to 84 (a)s.

The liquid crystal display panels according to Comparative Examples 1 to4 respectively have the same constitutions as those of the liquidcrystal display panels according to Examples 21 to 23 and 4, except thatthe specific structure 8 which can be recognized by an image recognitiondevice as a pattern does not exist. A projection part is formed on a BMlayer 61 d at the foot of the stacked PS 12 in the comparative examples1 to 4, but it is difficult to recognize the projection part by an imagerecognition device as a pattern, since the projection part overlaps withthe stacked PS 12 as viewed in plane, Therefore, according to theComparative Examples, a height of the stacked PS 12 cannot beautomatically measured with a PS height measuring device, since astructure which is recognized by an image recognition device as aspecified pattern does not exist on the substrate.

This Nonprovisional application claims priority (under 35 U.S.C. §119(a)) on Patent Application No. 2004-263091 filed in Japan on Sep. 9,2004, Patent Application No. 2005-124330 filed in Japan on Apr. 21,2005, and Patent Application No. 2005-215044 filed in Japan on Jul. 25,2005, the entire contents of which are herein incorporated by reference.

1. A substrate for a liquid crystal display panel comprising: aprojection structure including a single layer structure; a black matrixincluding a protrusion; a columnar spacer located in a regionoverlapping with the protrusion; a first portion where an outline of theprojection structure and one side of the protrusion intersect; and asecond portion where an outline of the projection structure and anotherside of the protrusion intersect.
 2. The substrate for a liquid crystaldisplay panel according to claim 1, wherein the projection structureincludes a dot-shaped protrusion arranged to control an alignment. 3.The substrate for a liquid crystal display panel according to claim 1,wherein each cell area includes the intersecting portion.
 4. Thesubstrate for a liquid crystal display panel according to claim 1,wherein the intersecting portion is substantially uniformly provided ona surface of the substrate.
 5. The substrate for a liquid crystaldisplay panel according to claim 1, wherein the substrate for a liquidcrystal display panel is a color filter substrate.
 6. A liquid crystaldisplay panel comprising the substrate for a liquid crystal displaypanel according to claim
 1. 7. A liquid crystal display devicecomprising the substrate for a liquid crystal display panel according toclaim
 1. 8. A substrate for a liquid crystal display panel comprising: aprojection structure including a columnar spacer; a depressionstructure; a black matrix including a protrusion; a first portion wherean outline of the depression structure and one side of the protrusionintersect; and a second portion where an outline of the depressionstructure and another side of the protrusion intersect; wherein thecolumnar spacer is located in a region overlapping with the protrusion.9. The substrate for a liquid crystal display panel according to claim8, wherein the depression structure includes a slit arranged to controlan alignment and/or a hole arranged to control an alignment.
 10. Thesubstrate for a liquid crystal display panel according to claim 8,wherein each cell area includes the intersecting portion.
 11. Thesubstrate for a liquid crystal display panel according to claim 8,wherein the intersecting portion is substantially uniformly provided ona surface of the substrate.
 12. The substrate for a liquid crystaldisplay panel according to claim 8, wherein the substrate for a liquidcrystal display panel is a color filter substrate.
 13. A liquid crystaldisplay panel comprising the substrate for a liquid crystal displaypanel according to claim
 8. 14. A liquid crystal display devicecomprising the substrate for a liquid crystal display panel according toclaim 8.